Method for making metal castings



March 26, 1929. F B FOSTER METHOD FOR MAKING METAL CASTINGS 5 Sheets-Sheet Filed -May 5, 1924 March 26, 1929. F. B. FOSTERv 1,707,117

METHOD FOR MAKING METAL CASTINGS Filed Mal 5, 1924 3 Sheets-Sheet 2 lNvENToYR 25' LW/MW v @ZT/MSW March 26, 1929. F. B. FosTER METHOD FOR MAKI'NG METAL CASTINGS Filed May 5, 1924 3 Sheets-Sheet Patented Mar. 26, 1929.

-FRANK B. FOSTER, F BEAVER, PENNSYLVANIA.

METHOD FOR MAKING METAL CASTINGS.

applicati@ mea my a, 1924. serial No. 710,771.

I My invention relates to methods for mak-l ing metal castings, and more particularl to the production of rolls with chilled iron wearing surfaces. t

.One object of the present invention is to provide a methodlinvolvin in its preferred adaptation va simple and e 'cient centrifu al casting machine which will make rolls so id from .a combinationl of metals, particularly l0 iron, and steel, or -alloys of either or both of them. To obtain a smoothfinish in the hot rolling of metals, ,particularly iron and steel, iron rolls with chilled surfaces are preferably used. The greatest defect of such rolls now in use is their comparatively low strength. It is one of m objects to produce a method for producing rolls of superior strength, and hardness of wearing surface. `Other objects appear hereinafter.

Fig. 1 is `a central longitudinal section of the preferred form of my casting machine in its horizontal position, parts being in side c elevation; Fig. 2, an end view of Fig. 1; Fig. `3, a horizontal section of Fig. 1 on the line III-111;V Fig. 4, a side elevation `of my machine in .its vertical position, a portion having been brokenaway; Fig. 5 is a side elevation of the outer end of my casting apparatus showing -al modification; Fig. 6, a similar view but showing the apparatus in a--vertical position; and Fig. 7 a sectional sdetail showing the slidable connection of the stand 29 with its support. l On the drawings 1 designates standards or supports on which are mounted the bearl ings 2 for the trunnions 3 of the cradle 4,

the vtrunnions being` horizontal and con nected to the opposite sides of the cradle intermediate of its ends, so that the cradle may assume horizontaljand vertical positions. For moving the cradle from one position to another on its trunnions,fI extend one of the trunnions beyond its bearing 2v and provide the extension with the worm-wheel 5, which is 'operated by the worm 6.

c .The cradle is' shown as ahollow cylinder with ltwo external annular hollow ribs or housings 7 opening into the hollow of the (.ylindery These housings contain each a `7 are the outwardly-extending projections '14 Referring tothe accompanying drawings,

bearing rib v19 arranged between two circu- 'lari series of thrust-bearing rollers 20 and 21 'series of rollers 8 supported in the radially movable bearing blocks 'or' slides 9 guided 4by the internal side walls. of the housings 7 and by the rods 10 which are parallel with the cradle axis and have their ends extcnd-v ing thro-ugh the' opposing faces of the ribs 7 and through the blocks 9 and the rollers therein. Each rod thus forms the axle for two opposite rollers in the two ribs. The opposing faces ofthe ribs have radial slots llffor the rods 10x80 that the latter may have free radial movement to a certain extent. On the peripheral. walls of the ribs which contain the compressed springs 12l bearing on the outer endsof the blocks 9. Screws. 13 threaded in the outer ends of they projections. 14 serve to adjust the pressure which the springs exert on the rollers 8, the latter bearing upon the annular ribs or riding rings 15 on the periphery of the rotary cylindrical metal mold body or flask 16, arranged within the cradle and concentric therewith. The lower end of theflask lis closed by the cap 17 which is preferably integral. with the downward. stem or extension 18 in axial alinement with the flask. The stem 18 has the peripheral or annular thrust Acarried `by the ring 22 secured in the lower end of the cradle 4. The lower end of the stem'18 is provided with the driven belt- Wheel 23 connected by the belt 24.- running over the pulley' 25 'driven at the desired speed bythe electric or other motor 26 attached to the lower portion of the cradle.

In the manufacture of a cast metal roll, I place inv each end of the flask 16 rings 27 of molding sand or the equivalent conformed in its dimensions and shape to the correspending dimensionsand shapes of the rol`l' necks to be cast, the space 28 between the sand-rings being left -bare as a chill for casting of the body of the roll against.

To` supplythe mold with molten materials I may provide a movable stand 29 having a horizontal o ening' 30 in --line with the end of the mol when in horizontal position, as shown in Fig'. 1. The standard carries` thehollow horizontal shaft 3l in aliuement 60 surface can be modified as to depth and with the .said opening and has at its outer end the Worm-wheel 32 having an opening y p in line with the hollow of the shaft 31. To the outer face of the wheel 32 is attached the plate or casting 33 which supports three ladles, 34, 35 and 36, arranged to discharge their contents into the tube 37 which is su ported by the plate 33 and projects into t ie space 28. The wheel 32 is rotated by the worm'37. The ladles have 'their bodies considerably eccentric of their discharge nozzles 38. and their filling openin 39 on the sides opposite their deepest portions. This structur'e allows each ladle to come to a position with its filling' opening up as is the case with theladle 34. In this positioii molten metal or other material may be deposited therein. Upon rotation of the wheel 32 the ladle 34 rises so as to discharge its contents, as cast-iron, into the tube 37 while the ladle 35 rises to its -iilling position. ,In a similar manner the ladle 35 containing steel,

. for example, isf discharged `and the ladle 36 brought to iillingposition, if required. Ma-

terials may be supplied to the mold in other ways.

' With the parts as shown in Figs. 1, 2 and 3, the motor' 26 isstarted and caused to rosuitable mixture of hot tate the flask-16 at the,desired speed. Molten cast-iron of the desired composition is introduced into the space 28 throu h the tube 37 or other suitable feeder. he rotation of the mold causes the iron to be forced radially outwardly so as to form a coat 3 8 on the inner face of the flask or mold surface in' the space 28. Moltencastiron is su pliedLto the space 28 until the desired tliic ness has been deposited on the in ner face of the mold. Then steel of the dey sired composition is supplied to the space 28,

the casting. I do not limit the process so as to require themold to be swung to its @vertical position just when the desired `de th of cast-iron has been cast or solidiie against .the mold wall; it should be swun to vertical positionpriorl tol the {illin fo a complete cross-section of the mold. he metal mold surface in the space 28 imparts a chilled surface tothe roll. This jother characteristics in obvious ways. I

l maycast a roll with a chilled` iron face and a steel shaft or core, ,as descri ed; or a roll with/ l aliigh carbon and high chromium face and low carbon steel coreu or shaft; or

ing sur aces having the hardest grade of chill,`and at the same time produce rolls from two to three times stronger than wou d be possible-with all-iron rolls.

Referring now to Figs. 5, 6, and 7,'tlie bracket 40 is carried by the.A lower side of the cradle 4 and at its outer end. The bracket extends downwardly for a short distance and then outwardly parallel with the cradle. The stand 29 is slidable on the upper surface of the outer portion of the bracket and is held and guided thereon by the dovetailed grooves 41 in the stand iitting the correspondingly-shaped ribs 42 connected by screws to the bracket, the ribs and grooves being parallel with the cradle. 4 A pair of toggle links 43 and 44 are pir-- oted together by the pin 45, the extreme ends of the links being pivoted to the cradle 4 and the stand 29 by the pins 46 'and 47, respectively. When the ap aratus is horii zontal, as shown in Fig. 5, t e stand 29 is at its left-hand position 'and the links 43anfl 44 are flexed upwardly. When the cradle is brought to itsvertical position, shown in -Fig. 6, the interconnected ends of the links opposite the pin 45 engage the stop 48, thereby causing the toggle/links to be straightened out, as shown in Fig. 6. This causes the stand 29 and the connected rts to move outwardly away from the' cradlii so that the discharge end of thel tube 37' will be withdrawn from the mold, thereby preventing the metal discharged through the tube as the cradle is elevated, from becoming fastened in the casting.

I do not limit the inventionl to an. particular means for swinging the cra le, or

for rotating the flask or tor to the liask oi' for supplying the mold with material in either position or to having the mold even substantially vertical during the second part `ot the process, as the metal'would lill the mold space when con sider'ably inclined except at the close-of the for gearing the mo` operation.l

1;"The 'method of casting' a roll with chilled working face which consists in pouring molten iron into a horizontal revolving mold having a chilling surface against which the molten iron is deposited by centrifugal force, and, after the iron so deposited has hardened. sufficiently to main-4 Ymold having a chilling lsurface against Which the molten iron is deposited by centrifugal force, and, after the iron so ldeposited has hardened sufiiciently to maintain the desired depth of chill in 'a fixed form, pouring into the moldmolten metal of a different composition from the cast iron, and moving the mold tovvard'a. vertical position while the casting is hollow.

3. The method of casting a roll' with chilled working face which consists in pouring molten iron into a horizontal revolving mold having a chilling surface against which the molten iron is deposited by -centrifugal force, and, after the iron so`deposited has hardened sufficiently to maintain the desired depth of chill in a fixed form, pouring molten steel into the mold,

and moving the mold toward a vertical position while the casting is hollow.

4. The method of casting a roll with chilled working face which consists in pouring molten iron into a horizontal revolving mold` having av chilling surface against which the molten iron is deposited by centrifugal force, and, after the iron so devposited has hardened suiciently tol maintain the desired depth of chill in a fixed form, moving the mold toward and finallyto a vertical position, molten metal bleing fed to the mold until the casting is made solid to thel desiredlevel.

5. TheV method of casting a roll with .chilled Working face vwhich consists in pouring molten iron into a horizontal 'revolving vmold having a chilling -surface againstv which the molten ironjis dept/)sited by centrifugal force, and, after thefiron 'so' deposited has hardened sufiieiently to nmaintain the desired depth of chill in a fixed form,

d moving the mold to a vertical position,

molten metal being fed to the mold until the casting is made solid to the desired level. l

6. The method of casting a roll with chilled working face which consists in pouring molten iron into ayhorizontal revolving mold having a chilling surface against which the molten iron is deposited by centrifugal force, and, after the iron so deposited has hardened sufficiently to maintain the desired depth of chill in a fixed form, pouring-into the mold molten metal of a different composition from the cast iron, and moving the mold toward and finally to a vertical position While the casting is hollow.

ldepth of chill in a fixed form, pouring into the mold .moltenmetal of a different compo# sition from the cast iron7 and moving the mold to a vertical position lwhile the casting is hollow. Y v

8. The. method of casting a roll with chilled working face which consists in pouring 'molt-en iron into a horizontal revolving mold having Va chilling surface against which the 'molten iron is deposited by centrifugal force, and, after the iron so deposited has hardened sufficiently to maintain the desired 'depth of chill in a fixed form, pouring molten st eel into the mold, and moving the mold toward and finally to a vertical position while the casting is hollow.v

A9. vThe method of casting aroll with chilled Working face which' consist-s in pouring molten ir-on into a horizontal revolving' mold havinga Achilling surface against which the molteniron is deposited by centrifugal force, and, aft-er the iron so deposited has hardened sufiiciently to maintain the desired depth of chillin a fixed form, pouring molten steel into the mold, andE moving the mold to a vertical position While the casting is hollow.

l0. The method lof casting a roll with chilled Working face which consists in pouring molten iron into a coreless horizontal revolving mold having a chilling surface against which the molten iron is deposited by centrifugal force, and, after the iron so deposited has hardened sufficiently to maintain the desired 'depth of chill in a fixed form, moving the mold V'from the" horizontal position and simultaneously feeding molten metal .to the mold until the casting-is lmade solid to the desired level.

11. The method of casting a 'composite metal roll Which consists in casting molten metal of one characteristicrby vcentrifugal action 'against' the interior srface of a hollovv rotating horizontal mold 'until -a predetermined thickness ofv metal has been so cast, and then moving the mold from the rhorizontal position and supplying the interior of the casting with molten metal of a different characteristic to the desired level. 12. The method of casting a composite metal roll which consists in casting molten metal of one characteristic by centrifugal action against the interior surface of a coreless hollow rotating horizontal mold to ob characteristic to the desiredV quantity.

13. The method of -casting a composite metal roll which 'consists in casting molten v metal lof `one characteristic by centrifugal action against the interior surface of a hol- 5 low rotatingl horizontal mold until a pre- In testimony whereof, I hereunto aix Iny signature this 24th day of April, 1924.

' FRANK B. FOSTER.

determined tliiclmess of metal has been so cast, and then: moving the xnold from the 

